Mailable package and method of manufacture



July 19, 1966 G. c. SPARKS MAILABLE PACKAGE AND METHOD OF MANUFACTURE Filed July 21, 1964 2 Sheets-Sheet 1 INVENTOR.

650/?6! C 5/34/9/(5' Mar/J6- M July 19, 1966 a clsPARks 3, ,456

- MAILABLE PACKAGE-AND METHOD OF MANUFACTURE Filed July 21, 1964 2 Sheets-Sheet? H HH H 'u u urmmmm1!!!1 I NVENTOR.

650/961? C SPA/PIS United States Patent 3,261,456 MAILABLE PACKAGE AND METHOD OF MANUFACTURE George C. Sparks, 101 Rorer St., Erdenheim, Pa. Filed July 21, 1964, Ser. No. 384,189 7 Claims. (Cl. 206-46) This invention relates generally to containers, and is especially concerned with mailable containers, usually of relatively thin or fiat configuration.

For many years the conventional mailable package has been a set-up box of about one-half-inch depth. While other maila-ble packages have been proposed, such as of fold-up corrugated construction, these have not found general acceptance as requiring costly handwork. Despite its common usage, the conventional mailable set-up box is objectionable as being easily squashed, breaking open at the corners, being difiicult to open, and for other reasons.

It is an important object of the present invention to provide a thin mailable package which overcomes the deficiencies of the prior-art packages, resists squashing and breaking open, affords effective protection and safety to the contents, permits of quick and easy unsealing and attractive opening to produce a blossom effect and provide ample space for advertising copy and design.

Other objects of the present invention will become apparent upon reading the following specification and referring to the accompanying drawings, which form a material part of this disclosure.

The invention accordingly consists in the features of construction, combinations of elements, and arrangements of parts, which will be exemplified in the construction hereinafter described, and of which the scope will be indicated by the appended claims.

In the drawings:

FIGURE 1 is a top perspective view showing a maila-ble package of the present invention in its transit condition;

FIGURE 2 is a partial sectional elevational view taken generally along the line 22 of FIGURE 1;

FIGURE 3 is a top perspective view showing the package of FIGURE 1 in partially opened condition;

FIGURE 4 is a top perspective view showing the package of FIGURE 3 fully opened;

FIGURE 5 is a plan view showing a blank adapted to be employed in the package of FIGURE 1;

FIGURE 6 is an enlarged, partial top plan view showing the instant package construction and illustrating an insert element of this invention;

FIGURE 7 is a sectional elevational view taken generally along the line 77 of FIGURE 6;

FIGURE 8 is a partial sectional elevational view illustrating the method of the present invention for use in manufacturing the packaging element of FIGURE 6;

FIGURE 9 is a later step in the instant method; and

FIGURE 10 is a bottom view of the element of FIG- URES 6 and 7, taken generally along the line 10-10 of FIGURE 7.

Referring now more particularly to the drawings, and specifically to FIGURES 1-5 thereof, a package of the present invention is generally designated in FIGURES 1, 3 and 4, and includes a one-piece cover 21, shown in blank form in FIGURE 5, and an article-carrying insert pad 22.

The cover 21 may be formed of an integral sheet of stiff, bendable material, such as paperboard, or the like, and cut and scored to define a generally rectangular back wall or panel 25 bounded on its opposite sides by generally parallel fold lines or scores 26, and at its opposite ends by generally parallel fold lines or scores 27. Extending outward from the side folds 26 are respective Cir 3,261,456 Patented July 19, 1966 side walls or panels 28, of generally rectangular configuration and relatively shallow dimension. Extending from opposite end folds or scores 27 are a pair of generally rectangular end Walls 29, of similarly shallow dimension. The sides walls 28 are each coextensive with the adjacent side fold 26, and the end walls 29 are each coextensive with the adjacent end fold 27.

The side walls 28 are each bounded on their inner side by the adjacent fold 26, and at opposite ends by edges 30 in respective alignment with end folds 27. An outer fold or score 31 extends between the end edges 30 of each side wall 28, generally parallel to the adjacent fold 26.

A generally rectangular top part or panel 32 extends from the outer fold 31 of each side wall 28, being longitudinally coextensive therewith and hingedly connected thereto. Each top part or panel 32 is defined within the bounds of the adjacent fold 31, a pair of end edges 33 extending from fold 31 in alignment with respective end edges 39, and a fold line or score 34 extending between the edges 33 generally parallel to the adjacent fold 31.

A generally rectangular holding panel or flap 35 extends from each fold 34 for hinged connection to the adjacent top part 32. Each holding fiap 35 is bounded within a respective fold 34, a pair of end edges 36 extending in parallelism substantially normal to the adjacent fold 34, and an outer side edge 37 extending between the end edges 36 substantially parallel to the adjacent fold 34. The end edges 36 may be slightly off-set inward with respect to adjacent end edges 33, so that each holding flap 35 is of a length slightly less than its adjacent top part 32.

Each end wall 29 may be of generally rectangular configuration, coextensive with its adjacent end fold 27, and bounded by the latter fold, a pair of side edges 40 extending generally normal to the adjacent end fold in respective alignment with sidefolds 26, and an outer fold 41 extending between edges 40 generally parallel to adjacent fold 27. A pair of end flaps or tabs 42 are disposed in side-by-side, spaced relation along each fold 41, extending outward therefrom and combining to extend substantially the length thereof. That is, each sideby-side pair of end flaps or tabs 42 is arranged along and has its opposite ends coterminous with the edges 40 of a respective end wall 29, being spaced apart by a notch or cutout 43 opening outwardly from just inward of fold 41. The notches or cutouts 43 opening through respective folds 41 are in substantial alignment with each other longitudinally of the bottom wall or panel 25.

The insert pad 22 may be generally rectangular in outline configuration and substantially congruent to the bottom wall 25 upon which it is seated. The insert pad or body 22 may be of a height or thickness approximating the height of side walls 28 and end walls 29. In particular, the insert body or pad 22 includes an inner pad part 45 fabricated of resiliently compressible material, such as plastic foam, and provided with a skin or facing on at least one pad face. In the illustrated embodiment, the inner pad body 45 is provided on its lower and upper faces with respective skins 46 and 47, which may be fabricated of paper, or other suitable sheet material. The lower and upper skins 46 and 47 may be adhesively secured to the lower and upper surfaces of the inner pad body 45; and, the under or outer surface of lower skin 46may be adhesively secured to the bottom wall 25 to retain the insert body 22 in position on the bottom wall.

The insert body 22 is formed with one or more upwardly opening recesses 50 configured for comforma'ble reception of packaged articles 51. In the illustrated embodiment, a single recess 50 is configured to receive a plurality of articles 51.

In particular, the recess 50 is defined by an opening 52 formed in the upper pad face 47, and a depressed pad portion 53 beneath the skin opening 52. The recess 50 1s therefore bounded along its upper edge or rim by the bounding edge of skin opening 52, and by a side wall 54 of resiliently compressible pad material.

The packaged articles 51 may be snap engaged downward through the opening 52 of skin 47 and into recess 51, wherein the recess side walls 54 are resiliently compressible and distensible outwardly by the article 51, as best seen in FIGURE 7. It will there be apparent that the article 51 is effectively retained in position within the recess 50 by engagement of the sides of the article against the recess side wall-s 54 to depress the same beneath the bounding edges of skin opening 52. The skin material 55 removed to form the skin opening 52 is depressed with the nether pad region 53, and thus spaced below the skin 47 to form the bottom wall of recess 50. As the nether pad portion 53 is depressed beyond its elastic limit, the cutout skin area 55 remains in its lowered position.

With the articles 51 thus engaged in the insert body 22, and the latter secured in position on the bottom wall 25, the package is completed by moving of the end walls 29 upward and swinging of the end tabs 42 inward to overlie end portions of the insert body 22. The holding flaps 35 are then swung inward about the fold lines 34, and the side walls 28 swung upward about their hinged connections 26.

The top parts or panels 32 may then be swung over the insert body 22 and the holding flaps 35 engaged through opposite notches 43 and beneath tabs 42 to underlie their respective associated top parts. The top parts are thus effectively retained in closed position by engagement of the end tabs 42 between each top part and its adjacent underlying holding flap. This condition is shown in FIG- URE 1, wherein the closed package 20 may be sealed by a tape 60, if desired, extending between top parts 32 across the contiguous folds 34.

The closed package '20 in FIGURE 1 may be readily opened by severing the tape 60 and swinging the top parts 32 outward to disengage the holding flaps 35 from beneath tabs 42. Further outward swinging of the holding flaps 35 relative to their adjacent top parts 32 completely opens the package in a blossoming manner, as in FIG- URE 4.

The method of manufacturing the insert body 22 is shown in FIGURES 8, 9 and 10. A cutting die is shown in FIGURE 8, including a bedplate 65, upon which rests a sheet of resiliently compressible pad material 45 having lower and upper skins 46 and 47 adhesively secured in facing engagement with its lower and upper surfaces.

A movable press element 66 carries a die part 67 having a cutting edge 68 for severing the peripheral edge of an insert body 22. Also carried by the movable press element 66 is a die part 69 having a serrated cutting edge 70 of a configuration conforming to the outline of recess 50. The serrated edge 70 may depend slightly less than the outline-cutting edge 68, for a purpose appearing presently. Conforma'bly within the recess-cutting element 69 is a recess-depressing element 71 having adownwardly facing surface 72 spaced below the downwardly facing surface 73 of press element 66.

Upon downward movement of the press element 66, as shown in FIGURE 9, the die element 67 may pass completely through the upper skin 47, resilient pad 45, and lower skin 46 to completely sever the same and may engage in the bed 65, if the latter is of rubber or other similar bed material. However, the serrated cutting edge 70 of recess-cutting die 69 does not completely sever the pad 45, upper skin 47 and lower skin 46, but only severs upper skin 47, pad 45 and partially severs lower skin 46. That is, the serrated cutting edge 70 passes partially through lower skin 46 to perforate the same without complete severance. Also, the lower surface 72 of depression element 71 engages with the cutout area 55 of upper skin 47 to depress the latter and its nether pad region 53. The pad region 53 is thereby compressed beyond its elastic limit and remains depressed and in position Within the remainder of pad 45 upon removal of the depressing element 71. Thus, upon separation of the press element 66 and the dies carried thereby from the bed member 65, the material operated upon may be employed as an insert body 22. The perforations formed by the serrated diecutting edge are best seen in FIGURE 10 and there designated 73.

From the foregoing, it is seen that the present invention provides a unique container or packaging device, and method of manufacture, which fully accomplish their intended objects and are well adapted to meet practical conditions of manufacture and use.

Although the present invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is understood that certain changes and modifications may be made within the spirit of the invention and scope of the appended claims.

What is claimed is:

1. A mailable container comprising a one-piece cover sheet cut and folded to define a back wall, end walls upstanding from opposite ends of said back wall, in-turned tabs on the upper edges of said end walls, side walls upstanding from opposite sides of said back Wall, top parts extending inwardly from said side walls over said tabs, holding flaps extending from the inner edges of said top parts beneath said tabs for holding engagement therewith, and an insert body arranged conformably within said cover sheet, said body comprising a resiliently compressible pad having an opening on one pad face, and a skin on at least said one pad face having an opening conforming to said pad opening, said pad and skin openings combining to define a recess with the bounding edge of said skin opening releasably retaining a yieldable article in said pad opening.

2. A packaging device comprising a resiliently compressible pad having an opening in one face, a skin on said one pad face having an opening generally congruent to said pad opening, said pad opening being defined by a recess having a bottom wall, and a skin on said bottom wall within said pad opening, said recess having an upstanding peripheral side wall of resiliently compressible pad material and extending about said bottom-wall skin, whereby an article in said recess is engageable into said recess side wall beneath the bounding edge of said skin opening for retention thereby.

3. A packaging device according to claim 3, said pad being fabricated of plastic foam, and said skin being of flexible sheet material.

4. A packaging device according to claim 3, said skin being of paper.

5. The method of manufacturing a packaging device, which comprises: providing a pad of resiliently compressible foam material having a covering sheet on at least one face, severing said covering sheet along a predetermined outline configuration, severing the adjacent pad material generally congruently to said outline configuration, and depressing the sheet region within said outline configuration against the adjacent pad material to compress the latter beyond its elastic limit, to thereby define a recess having resilient side walls of said pad material and bounded about its outer edge by the severed edge of said covering sheet.

6. The method according to claim 5, further characterized in effecting said depressing subsequent to said severing to localize compression of the pad material within said outline configuration.

7. The method according to claim 5, further characterized in gradually effecting said severing with a serrated cutting blade.

(References on following page) 5 6 References Cited by the Examiner 2,797,806 7/1957 Davis 206-75 Fm 2,861,682 11/1958 Hatcher 206-75 UNIED snip/HES PATENTS 2,885,073 5/1959 Bettoli et a1. 206-60 3/ 1923 Pmkerton 229-27 7/1934 Boeye 229-43 12/1935 Myers 229 16 5 LOUIS G. MANCENE, Przmary Examzner. 12/1955 Wheeler 21753 W. T. DIXSON, Assistant Examiner. 

1. A MAILABLE CONTAINER COMPRISING A ONE-PIECE COVER SHEET CUT AND FOLDED TO DEFINE A BACK WALL, END WALLS UPSTANDING FROM OPPOSITE ENDS OF SAID BACK WALL, INTURNED TABS ON THE UPPER EDGES OF SAID END WALLS, SIDE WALLS UPSTANDING FROM OPPOSITE SIDES OF SAID BACK WALL, TOP PARTS EXTENDING INWARDLY FROM SAID SIDE WALLS OVER SAID TABS, HOLDING FLAPS EXTENDING FROM THE INNER EDGES OF SAID TOP PARTS BENEATH SAID TABS FOR HOLDING ENGAGEMENT THEREWITH, AND AN INSERT BODY ARRANGED CONFORMABLY WITHIN SAID COVER SHEET, SAID BODY COMPRISING A RESILIENTLY COMPRESSIBLE PAD HAVING AN OPENING ONE ONE PAD FACE, AND A SKIN ON ATA LEAST ONE PAD FACD HAVING AN OPENING CONFORMING TO SAID PAD OPENING, SAID PAD AND SKIN OPENINGS COMBINING TO DEFINE A RECESS WITH THE BOUNDING EDGE OF SAID SKIN OPENING RELEASABLY RETAINING A YIELDABLE ARTICLE IN SAID PAD OPENING. 